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Resistance Welding

Resistance welding is a thermo-electric process in which heat is generated at the interface of the parts to be joined. This is done by passing an electrical current through the parts for a precisely controlled time and under a controlled pressure, also called force. The name “resistance” welding derives from the fact that the resistance of the workpieces and electrodes are used in combination or in contrast to generate the heat at their interface.

Key advantages of the resistance welding process include:

  • Very short process time
  • No consumables, such as brazing materials, solder, or welding rods
  • Operator safety because of low voltage
  • Clean and environmentally friendly
  • A reliable electro-mechanical joint is formed

Heat generation process

Resistance welding is a fairly simple heat generation process: the passage of current through a resistance generates heat. This is the same principle as used in the operation of heating coils. In addition to the bulk resistances, the contact resistances also play a major role. The contact resistances are influenced by the surface condition (surface roughness, cleanliness, oxidation, and platings).

Four primary parameters influence the quality of resistance welding and need to be monitored closely to achieve best-in-class results: 

  • Materials
  • Energy
  • Weld Force
  • Time

Resistance Welding Equipment

The correct choice and control of the process energy, the supply of the energy to the parts that are to be joined and the exact follow-up of the welding electrodes all play important roles in the quality of the micro weld. The precise functioning of the weld heads is decisive. MacGregor Welding Systems offers a high-quality portfolio of various weld heads and power supplies to implement all the tasks involved in the resistance welding process.

MacGregor Welding Systems offers a wide range of welding methods, such as Spot Welding, Parallel Gap Welding, Projection Welding, Thermocompression Welding, Strand Welding and Insulated Wire Welding.

Common applications can be found in motor connections, cables, lighting components, battery tabs and sensors.

Learn more about the feasible technical options for resistance welding from our Weldability Chart

Weldability Chart

Resistance Welding applications.jpg

Resistance Welding applications:

  • Motor connections
  • Connectors
  • Cables
  • Lighting components
  • Battery tabs
  • Sensors